Wednesday, April 28, 2010

02B 5th gear swap

Today was rather truncated due to family needs, but I was able to dive into the 02B tranny and swap the 5th gear set with the passat 02A tranny giving me a .756 5th instead of the EV .837.

Here's how it unfolded:

02B on left, 02A on right, with 5th gear cover the black cover with the VW logo.

Next it's off with the covers. 5th gear set sitting high and proud.

Here's the syncro slider hub pivot bolt being removed. Both pivot bolts must be removed (triple square head, 18 ft/lb torque spec) as well as the attachment point at the shift lever which requires a long T45 bit (also 18 ft/lbs).

Slider hub still attached to gear set.

Slider yoke removed. Next step is to take off the slider hub, but first it is wise to mark (1, 2, 3) the 3 locating tabs along with which slot they are riding in. Always reassemble the same way it came apart! Next remove the light duty C-clip that rides inside these tabs.

Next it's time to use the impact wrench to remove the big T60 bolt holding both the main gear set and the layshaft gear to their shafts. These are fairly tight (59 ft/lbs) and there's no good/easy way to keep the gears from turning, so the impact gun makes for handy removal. Once the bolts are off, time for the gear puller. The gears come off relatively easy and may even come off just by heating to 100*C. Be very careful not to break the teeth of the gear upon removal! They are fairly brittle in composition. Also, they have an alarming looking concentric notch (1 to 3 in each gear) in every tooth of the gear. This is normal and must be for even oil distribution while operating.

Main gear set removed, now it's time for the smaller gear. This one is a bit tighter fit to get a gear puller in place, especially on the 02B trans. since it is a few mm larger and space is limited. Be careful again not to break the teeth off! They are very fragile!!

Once you get this gear off, you can do the same procedure all over again on the 02A trans to get the 5th gears you need. Then you need to install it in the 02B trans, reversing this order of operations. Couldn't be easier right?